Diploma thesis is focused on machining of refractory ceramics materials. The theoretical part describes the division of ceramics materials, their structure, manufacture and properties. This part also contains the division of refractory ceramics. In the second chapter, of ceramics materials are described machining. The latest chapter is focused on analyzing the machinability of ceramics materials R - SLI - K. During the experiment, cutting conditions were changed and cutting forces were checked. Then surface roughness was measured and tool wear was observed.

Diploma thesis contains introduction of a company P-D Refractories CZ a. s., where the manufacture of ceramic chimney liners is. Followed by a description and analysis of the product in the entire production cycle, material and product spectrum. Based on the results of current production is created proposal to streamline the machining technology with a view to increase productivity and reduce defective products, which means determine the material of a tool and the method of machining. The work is finished by technical-economic assessment, where the summary and recommendation of the proposed solution are.

<p>Development of products which can be produced from a country’s natural resources is very important as far as the industrialization of a nation and saving foreign exchange is concerned. Presently, industries in Uganda and the other states in the Lake Victoria region import all refractory-related-consumables, as the demand cannot be met locally. Based on the abundance of ceramic raw materials for high temperature applications in the region and the demand for refractories by industries it is pertinent to develop and manufacture firebricks by exploiting the locally available raw materials.</p><p>This thesis thus, concerns the characterisation of ceramic raw mineral powders from the Lake Victoria region, more particularly, Uganda, with the aim of developing firebrick refractories from the minerals. Two main deposits of kaolin and a ball clay deposit were investigated to assess their potential in the manufacture of refractory bricks. Raw- and processed sample powders were investigated by means of X-ray diffraction (XRD), thermal analysis (DTA-TG) and Scanning Electron Microscopy (SEM). In addition, the chemical composition, particle size distribution, density, and surface area of the powders were determined.</p><p>A comprehensive study on beneficiation of Mutaka kaolin was carried out using mechanical segregation of particles. The aim of the study was to explore other potential applications like in paper filling and coating. The beneficiation process improves the chemical composition of kaolin to almost pure, the major impurity being iron oxide.</p><p>A general production process scheme for manufacturing fireclay bricks starting with raw powder minerals (Mutaka kaolin and Mukono ball clay) was used to make six groups of sample fireclay brick. Experimental results from the characterization of formulated sample bricks indeed revealed the viability of manufacturing fireclay bricks from the raw minerals. Based on these results, industrial samples were formulated and manufactured at Höganäs Bjuf AB, Sweden. Kaolin from the Mutaka deposit was used as the main source of alumina while ball clay from Mukono was the main plasticizer and binder material. The formulated green body was consolidated by wet pressing and fired at 1350°C in a tunnel kiln. Characterization of the sintered articles was done by X-ray diffraction, scanning electron microscopy, and chemical composition (ICP-AES). In addition, technological properties related to thermal conductivity, thermal shock, alkali resistance, water absorption, porosity, shrinkage, permanent linear change (PLC), linear thermal expansion, refractoriness under load (RUL), and cold crushing strength were determined. The properties of the articles manufactured from the selected naturally occurring raw minerals reveal that the produced articles compare favourably with those of parallel types. Thus, the raw materials can be exploited for industrial production.</p>

Development of products which can be produced from a country’s natural resources is very important as far as the industrialization of a nation and saving foreign exchange is concerned. Presently, industries in Uganda and the other states in the Lake Victoria region import all refractory-related-consumables, as the demand cannot be met locally. Based on the abundance of ceramic raw materials for high temperature applications in the region and the demand for refractories by industries it is pertinent to develop and manufacture firebricks by exploiting the locally available raw materials. This thesis thus, concerns the characterisation of ceramic raw mineral powders from the Lake Victoria region, more particularly, Uganda, with the aim of developing firebrick refractories from the minerals. Two main deposits of kaolin and a ball clay deposit were investigated to assess their potential in the manufacture of refractory bricks. Raw- and processed sample powders were investigated by means of X-ray diffraction (XRD), thermal analysis (DTA-TG) and Scanning Electron Microscopy (SEM). In addition, the chemical composition, particle size distribution, density, and surface area of the powders were determined. A comprehensive study on beneficiation of Mutaka kaolin was carried out using mechanical segregation of particles. The aim of the study was to explore other potential applications like in paper filling and coating. The beneficiation process improves the chemical composition of kaolin to almost pure, the major impurity being iron oxide. A general production process scheme for manufacturing fireclay bricks starting with raw powder minerals (Mutaka kaolin and Mukono ball clay) was used to make six groups of sample fireclay brick. Experimental results from the characterization of formulated sample bricks indeed revealed the viability of manufacturing fireclay bricks from the raw minerals. Based on these results, industrial samples were formulated and manufactured at Höganäs Bjuf AB, Sweden. Kaolin from the Mutaka deposit was used as the main source of alumina while ball clay from Mukono was the main plasticizer and binder material. The formulated green body was consolidated by wet pressing and fired at 1350°C in a tunnel kiln. Characterization of the sintered articles was done by X-ray diffraction, scanning electron microscopy, and chemical composition (ICP-AES). In addition, technological properties related to thermal conductivity, thermal shock, alkali resistance, water absorption, porosity, shrinkage, permanent linear change (PLC), linear thermal expansion, refractoriness under load (RUL), and cold crushing strength were determined. The properties of the articles manufactured from the selected naturally occurring raw minerals reveal that the produced articles compare favourably with those of parallel types. Thus, the raw materials can be exploited for industrial production. / QC 20101029

The thesis deals with the possibility of utilization of fluid ash in refractory materials and its influence on resulting properties. This work studies the effect of bed and filter ash addition on properties of the droplet and resulting mechanical properties, bulk density, shrinkage and firing temperature of stove fireclay. The subject of this thesis is also reduction of SO2 emissions evolved burning of fireclay containing fluid ash rich of anhydrite. Emissions of SO2 were observed by TG-TDA-EGA method. Characterization of prepared samples and study of heat treatment processes was based on XRD, TG-DTA-EGA, TDA, SEM–EDS, heating microscope and isothermal calorimetry.

With the growing trend of construction, the demand for building materials is growing steadily. Porous concrete is widely used in the building industry, that makes efforts to discount production and simultaneously save the environment. The aim of this thesis is to develop high-quality porous concrete by using alternative raw materials as a substitute for silicate sand. As a possible substitute were chosen: Silica masonry, foundry sand and fireclay boulders. The influence of two key parameters - the specific surface (130, 240 and 350 m2·kg-1) and the amount of silica sand substitution (10, 30 and 50 %) were monitored. Two autoclaving modes (7 and 12 hours of isothermal durations at 190 ° C) were tested. Based on the physico-mechanical and mineralogical characteristics of the porous concrete composites was chosen the ideal surface area of 240 m2·kg-1 and time of isothermal endurance was determined at 7 hours (temperature 190 ° C, pressure 1,4 MPa). From the optimal intentions were created samples with a macroporous structure, using an aluminum powder. Physical-mechanical properties and microstructural analysis (XRD, SEM) were subsequently determined on the samples. Ideal recipes were proposed with 50% sand substitution of fireclay boulders and 10% substitution of foundry sand. This was due to a 10% higher compressive strenght and an increase of the coefficient of constructiveness, compared to the reference sample.